April 5, 2005 

'Inside Hydraulics' Newsletter

1. Seal Saver is customer saver
2. The anatomy of vane pump failure
3. Choosing the right hydraulic fluid
4. Content for your web site or e-zine
5. Help us spread the word
6. Tell us what you think


Seal Saver is customer saver

Damaged cylinder rods and wiper seals are an eternal problem for users of hydraulic machinery. Dents and gouges on the rods' surface reduce seal life and give dust and other contaminants an easy path into the hydraulic system.

This problem is compounded for hydraulic equipment rental companies. Under a typical rental agreement, the customer is liable for any cylinder damage during the rental period. If the cylinder rod sustains even relatively minor damage the customer can end up paying for a cylinder rebuild. The result is often an unhappy customer who will likely not return to rent again.

Disgruntled rental customers have become a thing of the past for New Millennium Rentals who have had their entire fleet protected with Seal Saver and according to Peter Menner, New Millenium's President, they haven't had a damaged or failed cylinder since installing Seal Saver five years ago.

Seal Saver is a continuous piece of durable material, which wraps around the cylinder and is closed with Velcro. It is then clamped onto the cylinder body and rod end. This forms a protective shroud over the cylinder's rod as it strokes and prevents buildup of contaminants around the wiper seal - a common cause of rod scoring, seal damage and contaminant ingress.

Seal Saver in action

Peter Menner of New Millenium Rentals showing
Seal Saver installed on an excavator bucket cylinder.

Research has shown that the cost to eliminate contaminants is 10 times the cost of exclusion. This combined with the benefits of extended cylinder rod and seal life makes Seal Saver a cost-effective, proactive maintenance solution - whether you are in the equipment rental business or not.

For more information, application photos, machine listings and a printable specification sheet, visit www.sealsaver.com Alternatively, call 1-800-683-5189 or send an email to sealsave@mindspring.com to request a complimentary Seal Saver video.

2.   The anatomy of vane pump failure

One of our readers wrote to me recently regarding the following problem:

"Recently, we bought a used hydraulic power unit (15HP electric motor directly coupled to a vane pump). A high pitched, clicking noise is generated when the unit runs. We have checked the following:

  1. We thought it was a motor bearing, so we detached pump from motor, no noise heard.
  2. Pressure line was connected to tank line (to simulate low pressure < 100 psi), very little noise heard.
  3. As pressure is increased, noise gets louder and louder, very intolerable.
  4. Measured current draw of motor - no overload.
What do you think could be causing the excessive noise?"

Given that the symptoms described above are consistent with a restriction at the pump inlet, I inquired if there was a suction filter in the circuit. Our reader replied:

"The system has a 40 micron suction filter but I haven't checked it because I have to drain the oil and take off the access hatch to get to the filter."

The restriction caused by a suction filter, which increases at low fluid temperatures (high viscosity) and as the element clogs, increases the chances of a partial vacuum developing at the pump inlet. Excessive vacuum at the pump inlet causes cavitation erosion and mechanical damage.

Cavitation erosion

When a partial vacuum develops in the pump intake line, the decrease in absolute pressure results in the formation of gas and/or vapor bubbles within the fluid. When these bubbles are exposed to elevated pressures at the pump outlet they implode violently. When bubbles collapse in proximity to a metal surface, erosion occurs. Cavitation erosion contaminates the hydraulic fluid and damages critical surfaces.

Mechanical damage

When a partial vacuum develops at the pump inlet, the mechanical forces induced by the vacuum itself can cause catastrophic failure. In vane pump designs, the vanes must extend from their retracted position in the rotor during inlet. As this happens, fluid from the pump inlet fills the void in the rotor created by the extending vane. If excessive vacuum exists at the pump inlet - it will act at the base of the vane. This causes the vanes to lose contact with the cam ring during inlet, and they are then hammered back onto the cam ring as pressurized fluid acts on the base of the vane during outlet (figure 1). The impact damages the vane tips and cam ring, leading rapidly to catastrophic failure.

vane pump section

Figure 1. Vane pump section (Bosch Rexroth Corp).

The intolerable noise our reader is referring to is symptomatic of cavitation bubble collapse and the vanes being hammered against the cam ring. Both of these conditions are intensified by increasing system pressure.

The solution to our reader's problem is simple: replace the suction filter or better still, discard it completely. If suction filtration must be installed, follow these precautions to prevent pump damage:

  • A filter located outside of the reservoir is preferable to a suction strainer. The inconvenience of servicing a filter located inside the reservoir is a common reason why suction strainers go unserviced - until after the pump fails.
  • If a suction strainer is installed, opt for 250 microns rather than the more common 150 microns.
  • The filter should be grossly oversized for the pump's flow rate to ensure that pressure drop is minimized, even under the most adverse conditions.
  • Regardless of the type of filter employed, it must incorporate a bypass valve to prevent the element from creating a pressure drop that exceeds the safe vacuum limit of the pump.
  • A gauge or transducer should be installed downstream of the filter to enable continuous monitoring of absolute pressure at the pump inlet.

Editors note - To learn more about hydraulic failures and how to prevent them, join Brendan Casey for a practical, half-day workshop on how to prevent hydraulic failures, to be held in San Antonio TX, April 25, 2005 and hosted by Lubrication Excellence 2005. For more information, visit the LE2005 web site or call 800-597-5460 or 918-749-1400.
Can't make it to Texas? Get the Workshop manual here.

"Thanks for the great work on the two publications, Insider Secrets to Hydraulics and Preventing Hydraulic Failures. I have been in the hydraulics business for the past 20 years and it is very difficult to find any decent material on hydraulic maintenance, troubleshooting and failure analysis. These two books cover it all in easy to understand language... I conduct hydraulic training courses and plan to purchase copies to distribute to my students to share your practical approach to understanding a not so understandable subject."

Paul W. Craven, Certified Fluid Power Specialist
Motion Industries, Inc.

3.   Choosing the right hydraulic fluid

For tips on choosing the right hydraulic fluid, read Brendan Casey's article in the January-February 2005 Issue of Machinery Lubrication magazine, available here. To receive a complimentary subscription to this informative magazine (US and Canada only) go to: http://www.machinerylubrication.com/hydraulic1.asp

4. Content for your web site or e-zine

Need some fresh content for your web site or e-zine? You now have permission to reprint these 'Inside Hydraulics' articles on your web site or in your e-zine, provided:

1. Each article is printed in its full form with no changes.

2. You send an e-mail to editor@hydraulicsupermarket.com to advise us where you'll be publishing them.

3. You include the following acknowledgement at the end of each article:
About the Author: Brendan Casey has more than 16 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his web site: http://www.InsiderSecretsToHydraulics.com

5. Help us spread the word

If you've found our 'Inside Hydraulics' newsletter interesting and informative, then chances are you have a colleague who would too. Help spread the word about 'Inside Hydraulics' by forwarding this issue to a colleague. If they share your interest in hydraulics, then they will surely appreciate being told about this newsletter.

New subscribers can get the newsletter by completing the form at http://www.insidersecretstohydraulics.com

6. Tell us what you think

We would love to hear what you think of this issue of our 'Inside Hydraulics' newsletter. And of course, if you have any suggestions for future issues, please send us those too.

Just e-mail the editor at: newslettersuggestions@hydraulicsupermarket.com

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